Heavy Copper PCB
A heavy copper pcb is a thicker PCB that requires different techniques than standard circuit boards. It starts with etching copper foil and plating to add planes, pads and traces.
These circuits can carry a high amount of current and withstand recurrent thermal cycles. They are in high demand for computer, automotive, military and industrial controls.
1. High Conductivity
Copper is an excellent current conductor that works well in PCBs. However, it does not provide the same thermal endurance as silver or iron. This is mainly due to the fact that it generates a lot of heat during its operation. Nevertheless, this can be dissipated with the help of thermal vias. This helps in minimizing the excessive heat and improving performance.
Printed circuit boards carry current through etched copper tracks. The copper thickness determines the current carrying capacity of the traces. Its current-carrying capacity increases with its width, but it is difficult to increase the copper width of a trace without affecting the impedance. Thus, a high-quality copper PCB should be plated with heavy or thick copper.
PCBs made of heavy copper are used in a variety of applications, including rail traction systems, UPS systems, solar power, and welding equipment. They offer exceptional performance and value in harsh conditions. They also deliver better reliability and consistency than standard copper circuits. This is possible because of their superior current conduction. They also reduce the size of appliances, allowing them to perform their jobs in compact sizes.
2. High Thermal Resistance
Heavy copper PCBs are designed to handle a high current, which generates heat. These PCBs can transport that heat away from sensitive components, helping protect the circuit. They can also help dissipate the excess heat in the assembly, ensuring proper function.
The increased thickness of heavy copper circuit boards enables them to withstand higher power levels than standard FR4 PCBs. They heavy copper pcb can also support more complex switches without compromising board design and assembly processes. However, this requires advanced plating techniques and specialized etching. Otherwise, the copper features may suffer from uneven trace walls and intolerable undercutting.
Traces that are too thin generate excessive power loss and raise the temperature of the copper, whereas thicker traces keep temperatures low through conduction and convection. The designer must determine the copper weight, trace width and current carrying capacity before choosing a substrate material. It should have a low thermal expansion coefficient to avoid cracks and layer separation, a high glass transition temperature to withstand the high mechanical stress delivered through plated holes, and a good thermal conductivity.
The use of exotic materials in PCBs can create a need for higher tolerances, and heavy copper helps these materials perform to their full potential. It prevents the high current from creating excessive heat, which can lead to circuit failure.
3. High Structural Durability
In printed circuit boards, copper traces carry current through the circuit. The width of these traces affects the amount of heat they generate and the maximum current they can carry. This is why heavy copper PCBs are used in devices that require high currents, such as power converters and computer controls.
Unlike standard copper traces, heavy copper conducts heat better and can support larger currents without weakening. However, these traces must be as short as possible to minimize resistance and power loss. This requires specialized etching techniques that can produce straight sidewalls and negligible undercutting.
PCB designers must gauge the amount of current they require and choose their design accordingly. They can use a trace width calculator to determine the appropriate thickness of copper and its maximum temperature rise. They must also consider the maximum current capacity of the board. This information is helpful in determining whether or not heavy copper PCBs are the right choice for their applications. The increased thickness of these PCBs requires specialized manufacturing technology and more expensive materials. However, they can deliver high-quality performance in various environments.
4. Low Failure Rates
The use of elevated current in modern circuits produces heat that needs to be dissipated. Since copper is an excellent conductor, it helps in pulling the excess heat away from crucial components. This prevents them from overheating, which is a common cause of PCB failure. The ability of heavy copper to transfer heat makes it a perfect choice for high-current applications. It is especially useful in industries that require high-current power distribution, such as military/defense, automotive, welding equipment, solar panels and industrial controls.
Standard PCBs are produced with a combination of etching and electroplating processes to increase copper thickness for traces and planes. These boards are also plated to increase their surface area. Heavy copper PCBs are manufactured with a double-sided or multilayer design that requires different etching and plating processes.
Heavy copper circuit boards are designed to withstand frequent exposure to high current, elevated temperatures and recurrent thermal cycles that can destroy ordinary PCBs in seconds. The ability to survive these conditions and their recurrent cycling allows heavy copper PCBs to provide the reliability that is essential in harsh environments.
5. High Thermal Dissipation
While copper circuits carry current, they also produce heat that needs to be dissipated. This is why many manufacturers opt for heavy copper pcbs as their fabrication process offers a Heavy Copper PCB Supplier high level of thermal conductivity and resistance. These are used in devices with high currents that require thicker copper and larger cross-sectional areas.
Unlike standard PCBs, thick copper circuit boards have more conductive layers and are typically manufactured using different processes. Plating and etching are utilized to add copper to planes, rails, pads, and traces before laminating these layers with prepregs like FR4 or Polyimide.
Due to the increased thickness of these layers, they can withstand higher temperatures and extreme current levels. In addition, they are known for retaining mechanical stress to enhance conductivity. This is important for the longevity of the board.
